Manufacture of mattresses



Nov. 23; 1937. J. R. JOHNSON 2,100,104

' MANUFACTURE oF MATTREssEs Filed Jan. 10, 195e y a sheets-sheet 1 Erg-1 ATTORNEY Nov. 23, 1937. 1 R, JOHNSON 2,1()@104 MANUFACTURE OF MATTRES SES Filed Jan. l0, 1956 8 Sheets-Sheet 2 INVENTOR BY MM-M i /TTORNEY Nov. 23, 1937. J. R, JOHNSON 2,100,104

i MANUFACTURE QF MATTRESSES Filed Jan. l0, '1936 8 Sheets-Sheet 3' INVENTOR j] En!T y .A c L n ATTORNEY Nov. 23, 1937. J R JOHNSQN 2,100,1@4

MANUFACTURE OF MATTRES SES yFiled Jan. 1o, 193e s sheets-sheet 4 105 /fifgy Y v-fzw 13 l O` 100 I ,gig/f, zzz

v INVENTOR M @u ATTORNEY Nov.- 23, 1937.

J. R. JOHNSQN MANUFACTURE OF MA'TTRESSES med Jari. 10, 1936 8 Sheets-Sheet 5 lNvENToR BY #www ATTORNEY Nov. 23, 1937. J. R JOHNSON l l 2,100,104

A MANUFACTURE OF' MATTRESSES Y Filed Jan. lO, 1936 8 Sheets-Sheet 6 INVENTOR am www I ATTORNEY Nov. 23, 1937. J. R. JOHNSON MANUFACTURE OF MATTRESSES 8 Sheets-Sheet 7 INVE NTOR BY Filed Jan. l0, 1936 ATTORN EY Nov. 23, 1937. L R. JOHNSON 2,100,104

MANUFACTURE OF MATTRESSES Filed Jan. 10, 195e 8 sheets-sheet 8 ATTORNEY Patented Nov. 23, 19H37' PATENT 'OFFICE A 2,100,104 MANUFACTURE oF MA'rrREssEs James. Reid: Johnson,New London, Conn., as-V signor to VThe Palmer Brothers Company, New

London, Conn., a corporation of Connecticut v 1 Application January 10, 1936, serial No. 58,524

'i "It cremas. (c1. 5-345) My invention` vrelates ,toA the manufacture of mattresses, and particularly to mattresses which embody a .pre-sewed casing into which a precon-f structed spring core is inserted through an aperture which is afterwards closed.

TObjectsfofv my invention are to syStematize, simplify.` and improve the successiveV steps of manufacture; to insure accuracy of workmanship,

Vsize'and` proportions; to prevent distortion; to nexpediteproduction;` toirnprovey the appearance, attractiveness, i eiciency ,and uniformity'V of the 1 mattresses; f to eliminate"` defects; andv ,to Asecure the other .advantages hereinafter described;

:.In :the .quantity i 1 production of mattresses, of the-character above mentioned, itis essential that azlstandard-size orsizesy of core shall be used, andthat?thejpre-sewncasing shall be accurately proportioned togreceiverand accommodate the corel without being. too" loose* or too tight, or wrinklingf or`..becoming.'distortedv when. the core is insertedv andz'thecasing finally closed. i'

arWhen the casing embodies broad layersof light, yielding. material', such as fibrous.v batting,v betweenftextilewalls, such as a facing and back- 1 ing,` it isqmost diicult'to cut `those textile walls,

kand ,theirinclosed batting in advance to accurate i ultimate asize. Fo`r,;rowing to the .yielding character of the batting andthe tendency torelative` displacement of the walls and, batting, ac-V curacy can notbe obtained byian operator. manneV Vallyassembling the partsgone by onev and securing them together by sewing;` Andthisgdifficulty, is.

increased where thewalls and batting `arequilted together;V becauserthe quilting `draws the walls 1. outpf iiat planes andshortensfor narrowsthe size i:

of the quilted piece.v Besides, vif. the quiltingisV dolle on irregular lines,.which are not equally disposedv over the whole extent of the Walls, thewalls will be locally` distorted, andtheir outlines will ffnotrcorrespondf withY their original contours; vand ifv the parts are then assembled, a distorted casing vwilLbe-the result.

,-Where ornamental casing-facings, eachcorm.v posed of Vseveral pre-cut,sections-- assembled and isewntogether so as toV form a design, are used,v distortion, due to such cutting,y assembling and sewing',isA emphasized; and, in addition, the ob jections above `mentioned toiv assembling units of"facing"battin'g and backingone by one are present in increased degree.

l It 1s my object to eliminate thesey d ifricunies andI defects :o manufacture, by the use of a 'system ofA progressive stepswhicli will produce, expeditiously, completefmattresses, uniform in type and accurate ijn vrrorlnn'anshifp. H

VIn the drawings, in allv of 4which similar parts are. designated by corresponding reference numerals, Fig. 1 is a. plan: view of a strip of textile.

material having anornamental design or pattern thereupon, and adapted to be cut into pieces which `may be reassembled into a panel-like design for the formation of a mattress-casing face; Fig. 2, shows such a panel; Fig. 3 shows a strip made by sewing. a pluralityA of suchwpanels end to end,

.medial portions beingexcised to shorten the 1`1g ure; Fig.v 4 is a top or bottom View of a completedf mattress casing; Fig. 5is a side view of the same, one corner being shown in section;Fig, 6

isa side elevation of an apparatus' adapted for use in joining the panels to each other; Fig.'7 is a plan view of the same; Fig. 8' is a perspective f View of a *plurality of panels joined end, to end,

and partially separated for clearness of illus' tration;A Fig. 9 'is a longitudinali elevation, and Fig. 10 is a plan showing, partially diagrammatically,

principalv elements for continuously assembling ythe batY and.- backing, tensioning, edge-sewing,`

I4 of Fig. 11; Fig. 15 is a horizontal sectional view taken on the line |5-*I 5 of! Fig. v"14, looking down, Fig. 16 is aside elevation of the principal elements of'quiltingxapparatus, suitable. for use in my` method; Fig. 17 is a plan view of the same;

Fig. 18 isa side elevation on an enlarged scaleV showing' a quilt-holdingl clamp; Fig. 19 is a plan taken on the line V21T-20 of Fig. 18.

, In carrying out my method I proceed as follows 'I take a strip oftextile material having upon one facea more `or less continuous, ornamental viewlof the samegand Fig. 20 isa sectional View Y Vdesign ordesigns, of a character that, when the Y strip has been cut into pieces and the pieces reassembled, a panel-like design may be obtained of. a` size: adaptedffor the formation of a mattress-casing face. For instance, ifv the strip 1 is cut across, at angles of forty-five. degrees, into triangles and sectionszhaving oppositely inclined ends and' straight side edges of moreor less length,

two of ythose long sections may be assembled with two of the triangular sections to form an elon-V Y v gated parallelogram of twice the width of the original stripV and with the ornamentation disposed in a panelled eli/ect. VSuch a strip I is shown in Fig. l, which may be cut at angles of forty-five degrees, for instance as indicated in broken lines .2, 2.

The sewing together of the sections making up such a facing, being done by an operator upon a sewing machine, by eye, involves certain unavoidable inaccuracies; so that, in practice, the outline of the panel is apt to be more or less distorted, andthe panel more or less wrinkled or puckered. This panel, also is aseparated unit, and, as such, it is not adapted for economical, practical, facing use. Such a panel 3 is shown' in Fig. 2. Y

I, therefore, join a number of these composite panels, 3, 3, end to end, into a 'continuous strip,

as indicated in Fig. 3, wherein medial parts, are 'Y omitted to shorten the figure, preferably employing an apparatus such as that shown in- Figsf and '7 of the accompanying drawings.

This apparatus embodies sewing means, and

means to be employed in holding a plurality of independent panels in assembled relation, and for successively presenting the proper ends of two panels tothe action of the sewing means,V

folding them back, and later successively'presenting the oppositey ends of dissimilarly mated panels for sewing together, so that a continuous strip of panels may be obtained. v

A conventional sewing machine may be employed, embodying a head Illand suitableV mech-V anism for operating a needle I I, shown as being arocking arm I2, reciprocated bya rod I3. driven by a cam I4 on a shaft I5 driven by` pulley I6, belt I1, pulley I8, shaft I9, carrying pulley 20actuated by belt 2l connected with a suitable source of power, not shown. f

Upon the flanged top 23 of a support 2li-slides a table 25 guided by extensions 26, 26 outside of the table support flanges; and having a rack 21 depending therefrom, adapted to mesh with a pinion 28 on a shaft 29 passing through a swinging arm 30, and loosely through a bearing 3|,and connected through pulley 32, belt 33 with pulley `34 fixed on shaft I9. v j

Through a pivoted pedal 35, arm 36, connect- Ving rod 31, arm 30 carrying bearing 38, ,the pinion 28 may be raised into mesh with rack 21,V or lowered away from the rack. A rotary feeder 39 on shaft 40 is connected through pulley 4| belt 42,- pulley 43 with shaft I9 and thesource of power.

' From the table 25 extend arms 44, 44 each having extendingmembers 45, 45, forming between them sockets, adapted to receive the standards 46, 46 of the panel carrying rack, mounted on `bases 41, provided with caster-rollers 48, 48, toV facilitate movement, the standards supporting aV top bar 49 adapted to have a number of superimposed panel sheets 3 hung over it andheld in place by akeeper bar 5ll placed above them and held in place by attached arms 5I, 5I straddling the top bar, so as to prevent the accidental displacement of the panels. This panel holding rack may be readily connected to the arms 44, 44 and held in place by pins 52, 52 passing through holes :in the extensions 45, 45 so that the panel carrying rack will travel along with the table 25, or may be readily released therefrom when the vpins 52, 52

are withdrawn.

Pivoted to brackets carried by the arms 44, A44 tis a pair of-lever arms 53, 53, connected byV a link 54, with an arm 55 fixed on a shaft 5B journalled in brackets carried by the tab-le 25, and provided with a fixed crank arm 51; and between the ends of the lever arms 53, 53 extends a rod 58 adaptedto lie upon the top of the table 25, or

to beV raised and ipped back and over the top of the panel support by movement of the crank arm 51.

I n' carrying out the joining of the panel sheets 3 into a continuous strip, I rst arrange them in a lsuccession of superimposed pairs, the first pair being placed, for instance, face to face, and the next pair back to back, and so on, the pack of panels being hung over Vthe top bar 49v and secured by the keeper bar 50, and the rack, carryin g the panel pack, being secured in position between the arms 44, 44. The end of the topmost panel is then flung back over the top of the keeper bar 50, as shown in Fig. 6. Over the rod 58, resting upon the table 25, are drawn the ends of the next two panels of the pack, that is the forward, by the operator, into proper position for presentation to the sewing machine, which is thrown into action by the operator, the table feed being simultaneously started, the movement being continued until the seam joining the ends of the two panels is completed, when thel sewing and feeding are stopped by the operator.

This movement of the table brings the handle of the crank arm 51 within convenient reach of the operator, who is positioned close to the sewing machine, and who then turns the crank so as to throw up the pair of sewed panels and iiip them back with a quick, tossing movement over the top of thekeeper bar 50 to hang down on its opposite side over the previously turned-back top panel. The rod 58 is then swung back to restron the table, which is returned bythe operator to its initial positio-n. The ends of the next two panels are then drawn onto the table,'over the rod 58 and are sewed together in the same Way as the preceding pair, andrthen flipped back; and this operation'is repeated until the bottom of the pack is reached, when there will be one odd panel left.

The panel rack is then. disconnected from the arms 44, and turned end for end, and again fastened tothe arms; and the sewed panel ends may be then turned b-ackinto their original positions.

'I'he ends of theuppermost panel and the next panel to it are thensewed together, in a similar manner to that already described, and the operation is continued until all the unsewed ends have been similarly unitedA in pairs; when all the panels of the pack will have Vbeen joined into a continuous strip, as illustrated in Fig. 8.

, This method results in the accurate, expeditious and uniform unitingfof the panels into a continuous strip which is conveniently folded for further operations. .f Y Y.

It avoids the clumsy, cumbersome work of sewing one panel after another to form a continuous roll or pack, which must be repeatedly manipulated by the operator, in a more or less loose and irregular form, the handling of which becomes more and more difficult as the sewing progresses, and is likely to produce undesirable irregularities and distortions of the work.

VClther'meansV than those illustrated mightbe employed for holding and moving and presenting the panels for the action of the sewing machine; and I have described the above mechanism only as showing one type wherewith thedesired re.- sults may be accomplished.

The continuous panel strip is now ready for continuous assembling with the bat and backing tensioning, edge-sewing and edge trimming, and cutting into panel length with the aid of suitable the rotary cutterwillbe caused to turn in theV apparatus such, for instance, .is sho-wn 1x1-.Figs 9, 10,111, 12, 13, 14, and 15. l

` Backing 60 is drawn forward from av source of supply, not shown, ina continuous strip,and .as itprogresses the bat 6I, from another source o-f supply, not shown, is spread on the backing, and travels with it, the continuous strip of facing Vpanels3, 3,- 3, being fed on top of the bat, which may be done readily by drawing from the folded l pack ofsewed panels, the assembled elements being pulled forward by rolls 63, 63, 64,v 64 which engage only with the margins of the assembly on each side, being `rotated by any suitable means, not shown, so as tor drawthe assembly forward.

i Longitudinal tension may be `provided by .any

suitable mechanical means, to place a drag upon y the backing and facing. But lateral tensioning, because of the bat, and the unavoidable wrinkling and puckering due to the previous sewing up of the panels, is not satisfactorily accomplished by mechanical means; so that it is found to be desirable to do this tensioning by the hands, as 65, 65, 66, 66, of the operators, stationed opposite to and pulling against each other, so as to present the assembly in a properly smoothed and ten.-

sioned condition for edge sewing near each edge byconventional sewing machines indicated at 61and 68. y

The edge-sewed assembly then passes a pair of rotary-cutters 69, 10, driven as by motors 1I, 12, Vwhich trim off the surplus edges, outside of the edge seams, soV as to leave the assembly with continuous, uniform, straight edges.

The edge-sewed and edgetrimmed assembly is then drawn forward by another pair of feed rolls, 13, 14 actuated by suitable means, `not shown, and allowed to accumulate somewhat in slack form before thernext operation, which is intermittent, and consists in severing the assembly into appropriatepanel lengths, in doing which suitable mechanical means may be utilized, such as that shown at the right in Figs. 9 and 10,

andin Figs. l1 to- 15.

This apparatus embraces table elements 15, 16 betweenthe opposed ends of which .is atransverse slot 11, above which swings a bar 18, carried by arms 19, 19, Xed on a shaft 80, `journalled-below the table 16, the bar 18 being depressible, through arm 8|, link 82 and pedal 83, and being raised, when free, by the spring 84between the arm 85 and the table frame 16. A rotary, toothed, disk cutter 81, is arranged to move back and forth in the slit 11,'being mounted on a carriage 88, traveling on a track 89, on rollers 90, 90, and

edge of the track 39, the cutter being actuated by a belt 92 running over a fixed pulley 93 on the shaft of the cutter 81, between.v idlers 94, 94 on the carriage, and over pulleys 95,v 96 on the frame f of the apparatus.

A shaft I -is mounted in the frame of the machine and carries an idler I 0I and two xed pulleys |02 and |03. It also carries xed pulleys |04 and 96. A driving `belt |05 runs over `the idler |0I, or pulleys |02, or |03.

Y On the shaft |01, journalled in the opposite end of the frame of the apparatus, are mounted fixed pulleys |08, |09, 95.

YOver the pulleys |04 and |08 runs a cross belt IIO.

Y It will be seen that when the belt is shifted in one direction, for instance, to the right in Flg.10, the rotary cutter will be caused to turnl one direction, and when the belt |05 is shifted in the opposite direction, for instance to the left,

' the frame of the machine.

steadiedby flanges 9|, 9| Vembracing the lowerv opposite direction.

In the frame of the machineismounted a gear |I2 meshing with a spur gearv I I3 on a shaft II4,`

journalled in the machine and carrying a pulley |I5,y around which and around the pulley 09 travels a belt I'I6. On an extension Ill of the bracket 'I I8, which carries the gear I I2, isV mounted aV take-up gear -I I9, and on the shaft |20, which carries the gear 2, is mounted another gear I2 I'; and still *another pulley |22 is. mounted on the shaft|00; and over the pulleys |09 and |22 and gears ||9 and I2I runs a sprocket chain |23, which is normally tight.

On the shaft ||4 is pivoted an arm |26 carrying a belt tightening pulleyV |21 which normally bears against the belt |I6. A rod |28 extends fromthe pivoted arm' |26 down to a connection with the pivoted arm |29 of the pedal 83 so that when the pedal is depressed the arm will be raised and the belt tightening pulley pressed against the belt II6 causing the belt, which has been loose and inoperative, to grip its pulleys and actuate the link belt |23 causing the rotary cutter carriage to travel.

The link belt |23 isfastened to the travelling carriage 80 and it has attached to it a stop I3| adapted to engagewith one end of a pivoted arm |32 so as to rock the armwhen the carriage has vtravelledY a sufficient distanceto the right .to bring the stopin contact'with the-arm.

This Vrocking of the arm actuates a belt shifter I 33, through connections hereinafter described, and throws the belty I5 onto the idler |0I and stops the rotation and travel of the rotary cutter. When the pedal 83 is depressed it draws down the rod 82, rocks the arm 8 I. and through its shaft 80 causes the arm |36 to move as tothe right in Figs. 14 and 15. This movement carrieswith it the T headed actuating rod |31 one arm |38 of the head of which will engage with 'a pin |39 on a three armed bell crank |40, one armItI Yof which isconnected to a slide k|42 carrying a cam slot |43 and travelling in a guide |44 attached to A pin |45 on an arm |46 of the bell crank |33, |46', pivoted to' the frame, as at |41 travels in the cam slot |43, the other `arm |33 of the bell crank |33, |46 constituting the shifter which controls the belt |05; so that by the retraction of the rod |31 the slide |42 will be drawn forward.

Thiswill move the belt shifter so as to shift the belt from its central position on the idler |0| to drive the pulley |02, causing the cross belt |I0` to turn the xed pulley |09=and the vpulley |09 to drive the belt||6 which, simultaneously with the shifting of the belt, has been tightened by means of the lever 83, pivoted at to the pedal 83 actuating the belt tightening mechanism already described. Y

The tightening of the belt causes vthe pulley I|5 to be turned, carrying with itthe pinion II3, which lmeshes with the gear I|2 turning with the sprocket I2I and driving the link belt |23 which travels around the pulleys |09 and |22, and is kept to duty bythe idler 9. The link belt carries besides the stop |3| another stop |50 the distance between -the stops corresponding substantially with the travel of the cuttercarriage 88 which is fastened to the link belt. The rotation of the pulley |09 causes the pulley 95, fixed on the same shaft, to turn, and drive the belt 92 whichtravels around the pulleys 95, 96, and between Vidlers 94, 94 and over a pulley 93 on the shaft `of the-rotary cutter, thereby. turning the the cutter.

cutter. 'I'his results in the travelling of the 'cutter carriage on its track, and the rotation `of the cutter, which movements continue untilthe stop |3| on the link belt encounters the pivoted arm |32 at the opposite side of the machine and rocks that arm causing its lower end, which projects through an opening in an arm |5| to rock that arm, and through it the shaft |52 mounted in the frame of the machine and carrying a rocking arm |53 one end of which is pivoted to one end of a link |54, the other end of which link is pivoted to the arm |55 of the three armed bell crank |4U.

The other end of the arm |53 is connected by link |56 with the rod |31. Consequently7 the rocking of the three armed bell crank by the pull of the rod |31 against pin |39 will draw the slide |42 forward so that the pin |45 will travel up in the cam slot, thus causing the belt shifter to shift the drive belt from the idlerto pulley |02. At the same time, the end of the arm |53 through the bell crank |40 draws the T-headed rod |31 sideways so that its arm |48 will be in a position to intercept the pin |49 on the three armed bell crank, when the arm |31 is again pulled forward by the depression of the pedal 83. Y Y

When Vthe carriage 88 travels to the right, the link belt |23 carries the stop |50 with it to the limit of travel of the'carriage. And when, on the depression of the pedal 53, the movement of the carriage is reversed and it returns'to its pre-V vious position, the stop |55 will engage and rock the pivoted'arm |32 causing the driving belt to be shifted into neutral position upon the idler ll.

In the cutting off step of my method it is important that the panel strip shall be severed into sections of approximately the right length, and on lines which will leave the panelled ornamentation properly balanced. It is also important that in cutting o the panels ythe materialsY of the panel strip should not be disarranged or distorted, but should retain their proper positions after the severance has been made. The fact that the backing andefacingrand the bat are not fastened to each other, except marginally,V

emphasize the likelihood of disarrangement or displacement under casual handling.

I, therefore, ind it necessary to positively hold the facing, backing and bat in their relative positions, against displacement, on both sides of the cutting line, and with vsuicient firmness to prevent the disarrangement'of the parts by And with the aid of suitable means, such, for instance, as the apparatus which I have last Vabove described, this can be satisfactorily accomplished because the assembled facing, bat and backing areV positively held against the tables on each side of the cutting line by the channel bar 18, so that the edge of the rotary cutter may sever' the assembly, the cutters edge turning freely in thespace of the channeL'and the edges of the materialen each side of the Vline of severance being left in their normal con- Y dition. The length of thesevered panel may be readily decided by the aid of a suitable stop or stops 62, 62, on the table 16 to which the free edge of the panel may be drawn before-the channel bar 18 islowered into place. which I have described expedites the cutting off operation by rendering it unnecessary to return the cutter from one side to the other of the apparatus or to readjust it for each successive'cutting xoperation; because the 1 cutter functions The apparatus Ytudinal yieldability, 'in order to avoidundue tenprevent changes in its outlines during the process 14 of quilting. Y

In Figs. 16 to 20, inclusive, I have illustrated elements of an apparatus'which may be employed to assist in this step of my method.

I-Iorizontally disposed frame bars |65, |60 are 1 provided with spring clamps |6|, |6|, each embodying a body |62, apivoted jaw |63, and closing spring |64. These clamps are disposed at the sides of the apparatus, being attached to the bars |66, |65, and may be provided with yieldable 2 pads, as |65, to avoid marring the panel.

Channelled end bars |56, |66 are disposed transversely relative to the side bars; and endholding bars |61, |51, Yadapted to register in the channels of bars |66, |56, are carried through 2 arms |68, |68, by shafts |66, |68, which may be rocked by means of crank arms |16, |16, connecting rods i'di. Vin', crank arms |12, |12, mounted on pivots |13, |13, and pedals |14, |14,

the bars |61, |61 Vbeing Vnormally depressed by 3 their own weight. 1

A conventional sewing machine head |11v (broken on" in Fig. I6) is carried by an arm |18 supported by a carriage |19 which may move transversely of the apparatus on track |16 in a 3 frame |30, mounted on rollers |8I, running on tracks |32 lengthwise of the apparatus, so that transverse and longitudinal motion will be imparted to the sewing'machine head. This may be done by hand or automatically, as desired, the 4 `means for driving the stitching mechanism, or

automatically directing the course of the sewing machine being omitted, as such means are well known in the art. f

Supporting straps |53, one rod |84 over rollers |85, |86, |81, |88, backV to the otherrod hill, and form a, shifting support below the fabric panel, leaving, however, an opening in the line of movement of the sewing machine head. By these means the sewing machine head may be moved bothV transversely and longitudinally, so that the needle may follow anyV desired line of stitching on the work.

Stitching along irregular or curved lines toV produce figures unequally disposed on the face of thepanel, will result in creating uneven tensions therein, because the facing and backing will be drawn toward each other along the lines of stitching. Thus, if an irregular design isrused,

tension will be increased in the areas where the f stitch lines are most numerous, Y as compared with areas where they are less numerous or where there are noV stitches. Y

Theside edges of the panel are held positively bythe edge clamps |61, |6i; but the end bars t |56, |61 permit a certain amount of slipping of the panel, if the quilting tension becomes too marked.

VMuch of the quiltingv tension is taken up, practically, in the panel body by compression of the 1 bat and adjustment of the facing and backing.

In practice, I haveY not found it necessary toi allow slipping of the panel material in the side clamps. But it is desirable to allow some longi;

V|33 each extend from 4 Wcloning:clue to irregular `lines of stitching. l.This

causes 4end' :edges of :the fpanel to assume Virregular :iines The?. propennallength' tof the .'panelftiskithe :distanceitbetweenithe opposed end ibars itil, t61; And "before .the quilted' ipanel4 is removdafrom vthe clamps, itf is fdistinctly vmarked along the inside edgesfcf the bars |61, `'I6-'I to `showthe?correct -endi-'lines of l,the panel. .The panel I1s .then 'removedifrom the frame .and a -line''of-w'stitchinglis runfacross nearfea-ch end of :the cpanel; rand'zthe VVends Aof the :panel 1 are :cut olf along/.the markedllineaso'that `the quilted panel is of the correctl `final length and width. Jllfechanism Isimi-lar 4to the sewing and f cutting mechanSmofFigS. 9 and 10, made'applicable to one edge on1y,:may:be usedin thisend sewing and trimming. v

vNlhile it ismostiimportant thatthe length of `the casing'shall bel accurately proportioned to Atlieleng'tlrof lthefcore which is very-.definitely ixed by the framework of the :spring assembly, the "casing mayaccommodate itself somewhat AIlaterally toithe core; by holding'the core some- -whatunder compression in the original assembly.

I'Some slightV transverse,y adjustment of the` casingwabout the core is alsopro'vided for by the .character of rthe. edgeboxing, `-whichlL preferably, use, and which is like the: facing units composed of a face, back and interposed bat held togethertby v.straight lines of stitches near each edge'y and 4byva plurality of intermediate andpar- 'allel lines ofstitchin'g, which negative longitudi- .nalfstretching `While allowing some degree of transverse `yielding-'in the-boxing.

Afilucha typecf-:edge boxing,.4, is shown in Fig. 5 of i the ydrawings;and :irregular lines of panel quilting Lare 'illustrated in broken lines 5, in Fig. 3.

, .if'Ifwofacing units are assembledA with-a box edgk ing unit1in-a casi-ng', by sewing their edges together and, preferably', taping them, all eight corners being rounded and completedfand allthe'seamsv closed except fal'ong'one' edge between corners, at one end.

The spring core is then flexed or folded upon itself lengthwise, and while held so folded is inserted through the open end seam ofthe casing, and when completely inserted is allowed to flatten out, progressively from its inner end; after which the end seam is permanently closed.

Means and method for accomplishing such insertion of the core are not part of the present invention, and are not therefore herein described.

By the use of the method which I have described I am enabled to systematize and expedite the production of mattresses provided with panel face casings composed of a plurality of joined sections, preferably cut from a strip of material much narrower than the finished casing panel; and also to combine such facing panels with suitable flling and backing secured together by ornamental stitching without distorting the contours of the panels; so that the panels may be of uniform shape and accurate proportions and shall be well adapted for use in the quantity production of mattresses of uniform shape and size.

In describing my improved method I wish it to be understood that I have emphasized the salient and lmore important steps employed; but that deand 'asl illustratingappropriate means for the practice of steps in my method; but areA not to be considered in anysense as exclusive means for the purposes mentioned.` :Having Vthus described myv invention what I claim, andxdesire'tosecure by LettersPatent of the United Statesfis: Y

#1f/In the methodofmaking a mattress the steps `of preparing .a plurality of disconnected 'similar oblong. panels, having ornamented faces exemplifying a closed .design and each sufciently large to form the top or bottom of a mattress; assembling a "plurality of the panels'in superim- "posedy pairs alternately face to 'face and back r to back; 4sewing together the adjacent ends of the .second panel of eachl pair and the first panel of the next pair; andV sewing together successively the other ends of each pair of panels, to unite the pane-ls'in .a continuous strip; assembling the continuous strip with a continuous bat and backing;

cutting the assembly into panel lengths approximately on'the lines of juncture of the panel sections; assembling the panelsv in pairs with a boxing to form mattress casings, and inserting cores therein.

"2. In the method of making a mattress the steps of preparing a plurality of similar oblong panels, having ornamented faces exemplifying a closed design and each suiciently large to form the top or bottom of a mattress; assembling a plurality of the panels insuperimposed pairs alternately face to face yand back to back; sewing together the adjacent endsof the second panel of each pair and the first panel of the next pair; and sewing together successively the other ends of each pair of panels, to unitey the panels in a continuous strip; assembling the strip, continuously with. a backing stripand .an interposed bat; tensioning the assembly laterally, manually; securing the elements-of `the assembly together marginally,` and ycutting Yitintov approximate panel lengths 'approximately on the lines of. juncture of the panel sections; cutting the panels to panel lengths, each including a closed design, assembling such panels in pairs with a boxing to form mattress casings and inserting cores therein.

3. The method of assembling a plurality of rectangular, similar panels having ornamented faces and dissimilar backs into a continuous straight strip, consisting in assembling a plurality of such panels in a pack of superimposed pairs arranged alternately face to face and back to back; and,

While the pack is so arranged, sewing together sucfolded back and forth upon each other is produced. l

4. In the method of assembling a plurality of independent, rectangular, oblong` sectional panels having dissimilar faces and backs,` each panel being somewhat longer than the ultimate, intended length, into a continuous strip for embodiment with continuous strips of bat and backing consisting in assembling a plurality of the panels in superimposed pairs alternately faceto face and back to back; sewing together the adjacent ends of the second panel of each pair and the i-lrst panel of the next pair; sewing together successively the other ends of each pair of panels, to unite the panels in a continuous strip; assembling the strip, continuously with a backing strip and an interposed bat; and sewing the same together, and afterward, cutting it into correct panel lengths approximately on the line of juncture of each pair of panels, so as to give panels that will each have a closed design thereon.

5. The method of making a mattress, consisting in preparing Va plurality of independent panels each having a closed panel ornamentation on one side and sufficiently large to form the top or bottom of a mattress; assembling a plurality of the panels in superimposed pairs alternately face to face and back to back; sewing together the adjacent ends of the second panel of each pair and the first panel of the next pair; sewing together successively the other ends of each pair of panels to unite the panels in a continuous strip; assembling the strip, continuously with a backing strip and an interposed bat; tensioning the assembly; edge sewing and edge trimming the assembly; cutting it into approximate panel lengths near the zones of juncture of said panel pairs, so as to include said closed panel ornamentation; positively holding each panel length marginally and quilting it in irregularmlines while so held; marking on the panel its correct, final end lines; sewing it along said lines; cutting each panel to proper nal length; uniting two panel sections with a boxing to form a round cornered casing completely closed except along one end edge seam between corners; inserting a self sustaining wire spring core through the opening, and then permanently closing it.

6. The method of making a mattress, consisting in preparing a plurality of independent panels each having a closed panel ornamentation on one side and suiiciently large to form the top or bottom of a mattress; assembling a plurality of the panels in superimposed pairs alter- Y nately face toface and back to back; sewing together the adjacent ends ofV thersecond panel of each pair and the first panel of the nextV pair; sewing together successively the other ends of each pair; of panels to unite/the panels in a continuous strip; assembling the strip, continuously with a backing strip and an interposed bat; tensioning the assembly; edgeA sewing and edge trimming the assembly; cutting it into approximate panel lengths near the zones of juncture of said panel pairs, so as to include saidrclose'd panel ornamentation; positively holding each pan'el length marginally but yieldable longitudinally and quilting it in irregular lines while scheld; marking on the panel its correct, final end lines; sewing it along said lines; cutting each panel to proper nal length; uniting two panel sections with a boxing to form a round cornered casing completely closed except along one end edge seam between corners; inserting a self sustaining wire spring core through the opening, and then permanently closing it. l

7. 'Ihe method of unitinga plurality of Vindependent, rectangular, textile, oblong, sectional panels having dissimilar faces and Vbacks into 'a continuous straight strip, consisting in Vassembling a plurality of such panels in a pack of superimposed pairs arranged alternately face to face andrback to back; holding the pack midway of its ends against displacement of the panels, sewing together the adjacent ends of a contiguous pair of relatively reversed panels on one end of the pack; turning such sewed Vends back over the body of the pack to give access to the next pair of panel ends; successively sewing and turning back in a similar way the ends ofthe remaining pairs of similarly disposed panels on the same end of the pack; restoring the sewed ends to their positions before sewing; successively sewing together and turning back on the pack the ends of each adjacent pair of panels on the other end of the pack; and restoring such sewed ends to their positions before the sewing, wherebya continuous straight strip of joined panels similarly faced and folded back and forth upon each other is produced. p Y Y v 'JAMES REID JOHNSON. 

